"The Hummingbird" Classic scrub hat with elastic

click here for download

This is a classic style of scrub hat. It has elastic in the back which makes it quick and easy to put on. It is fairly form fitting but not tight. If you have medium or medium/long hair you can still fit a ponytail in the back of this hat. I have a very medium size head and this feels just right for me. I took a tape measure and put it around my head just above my eyebrows, over the tops of my ears and around the back of my head. The measurement was 22 inches. If your head is a similar circumference then this hat should fit you too. At the end of the tutorial I will tell you how to adjust the fit if it doesn't feel perfect when you try it on. I would say this hat is fairly easy to make if you have some sewing experience.



Supplies needed for "The Hummingbird" classic scrub hat with elastic:
printer to print pattern out
tape to tape pattern sheets together
paper scissors to cut pattern out
cutting mat and rotary cutter for fabric or fabric scissors
sewing machine
thread
1/2 yard of fabric. (Cotton fabric is my favorite)
ruler to measure elastic
Five inches of 1/2" elastic (I like to use an elastic that is fairly thick because it is stronger)
some sort of fabric marking tool. (I use a water soluble fabric marking pen)
pins

Here are some more views of the classic scrub hat with elastic. Notice the front of the hat looks like it has a separate strip of fabric sewn on for the brim. Actually is is just folded up an sewn down. I think this is a nice added touch. It is one extra step but I think it improves the overall look of the hat. If you look closely at the fabric I used for this hat you will see there are hummingbirds on it. That is how I chose the name for this hat.

 Rear view: The middle section which is gathered is separate from the band. This allows for the brim to get flipped up while leaving the back unflipped. The gathered section would be too bulky if flipped up like the rest.

Although there are two small openings at the back which keep the middle section from flipping up when you create the brim they do not show. They get hidden in the gathers. (These small openings have finished edges)

Tutorial:

Here are step by step directions that should help you to sew your own classic scrub hat with elastic. This hat is composed of two pieces. The long narrow piece is what I refer to as the "front". The large circular piece is what I refer to as the "top".

First download the pattern and print it off. Tape the pages together as directed on the pattern pages.
Cut the pattern out on the solid lines.


Step 1: Place pattern pieces onto fabric pieces as directed and cut out.
Step 2: Follow directions as on "top" pattern piece by folding edge over 1/4" and pressing with an iron.
Step 3: Double fold this over another 1/4" and press again with an iron.
Step 4: Now stitch these folds down stitching close to the edge (seen in picture below)

Step 5: Fold the bottom edge of the "Front piece B" up 1/4" and press with an iron. Now double fold this up another 3/4" and press. Do not sew this down at this time. Next unfold again. Now it is time to make  lines where you want to anchor down the elastic.  Make a line 3 1/2" in from the Left hand edge and 3 1/2" in from the Right hand edge of  "Front  piece B".  (I use a fabric marking pen that erases with water).

Step 6.  Do steps 6 and 7 on one side only for now. Place elastic on fabric overlapping the line a little. As you can see I chose to do it on the Left side.

Step 7. Fold back up encasing the elastic. Be careful not to let the elastic move as you do this. Now put a pin in to hold the elastic in place or hold on tight making sure it doesn't shift as position it into your sewing machine.

Using a zig zag stitch sew at the marked line as seen above.

Step 8: Place the front and the top piece together. THE RIGHT SIDES OF THE FABRIC NEED TO BE FACING EACH OTHER. (wrong side facing you) The front piece should be on top. Place several pins to hold in place. You may need to pull on the front piece a little to ease it around the circular shape of the top piece. The fabric has a little give and stretch to it so this is not difficult to do.  Now stitch the two pieces together using a straight stitch and a 1/4" seam allowance. Go back now and zig zag stitch the edge to prevent fraying. (Or if you are lucky enough to have a serger just serge the two pieces together)

Step 9: Repeat steps 6 and 7 but on the other side.  (note I do not have a picture of this). At this point the bottom edge of "Front piece B" is connected by the elastic. The "tail" of "Top piece A" is still flapping loose.

Step 10: Sew all the way around the bottom edge of the hat close to the edge.

Step 11: Now it is time to create the brim. Flip the bottom edge up towards the front of the hat. I like to give it a press with the iron at this point. Now top stitch down in place close to the edge.

 Step 12:  Time to work on the bottom edge of "Top piece A" First iron this edge up 1/4". Then fold up another 3/4" and iron again. (This is exactly how you ironed the bottom edge of  "Front piece B" in step 5) Time to sew the little flap at the bottom of "Top piece A" with the elastic encased in it. You really need to pull on the elastic to stretch in out so that you can get it in the machine to sew it.

 Note: When I sewed this hat I did step 12 before I did step 11. It does work but you have to work the elastic a little to flip it because it is already encased in the middle portion. I realized later it would make more sense to do it in the order I described.

Now you are finished. Try on the hat. How does it feel? If it feels a little bit loose go to one of the openings at the back, pull on the elastic. Pinch it together until it feels like a good fit. Remove hat while keeping your fingers pinched on the elastic. Look how much elastic is in your pinched fingers. Put the elastic in the sewing machine and sew it in a little. Try it on again. Hopefully you have achieved the perfect fit.  Remember, you do not want it to fit too tight. I have made this mistake a couple of times and I just get headaches from wearing a hat that is too tight.